For the 12 years we've had this condenser unit the compressor leads
have burned off at the terminals once or twice a year. These events
burn the insulation off the wires back about 3 inches from the
connection, and seem to char the wire itself to the same point but it
may just be the burned insulation making it look like the wires were
For the 10 years my unit was under warranty I simply called the people
who installed it, they'd come out, cut off the burned wire ends add
some inadequate crimped on connectors and it would work for 6-12 more
months. Now that the warranty has run out this has become my job.
This summer it's begun doing this more frequently and the events seem
to be getting closer and closer together. I'm pretty sure this even
happen upon startup because I've heard the breakers snap a couple of
times shortly after the indoor fan comes on, and when I go out and
look the leads are burned.
Based on advice I got here I installed a set of Term-Loc leads about 6
weeks ago. A week ago these leads burned (just like the old ones).
The connectors stayed on but one lead burned completely off its
Term-Loc connector. The event melted/burned up the plastic terminal
separator that comes in the Term-Loc kit. I wasn't able to attach the
burned off lead to the Term-Loc connector again, so I went back to my
old method that used to last 6 months to a year. Night before last
the same lead burned off again.
My question is, what causes compressor leads to burn off of terminals
repeatedly like this? Remember it has been happening fairly regularly
for 12 years so it isn't a condition caused by age.
This unit has a black cylindrical thing connected to the run
capacitor. It has the name Supco Super-Boost. [See picture
http://img150.imageshack.us/img150/8528/supcop7315937gi9.jpg] It has
words on it that sound like it's a compressor start booster.
Suggesting it gives the compressor a big current hit on startup to
kick the motor into motion. Could this be causing the wires to burn?
If so, why do I need it and can I remove it? If I can remove it, do
I just disconnect it from the start capacitor?